Wovez-i bile



J. COLEY.

WOVEN PILE FABRIC.

APEUCATION FlLED APR. 11, 1911.

1 35 6b Patented May 27, 1919.

INVENTOR Jon 9h 60/ey BY WMR.

ATTORNEY 1 JFQSEPH 'GGJLEE, 0E FWQECES'EER, MASSACHUSETT$ Woven rrnnrannrc,

Specification of Letters Patent.

Patented May 27', 1Q1Q Application filed April 11, 1917. Serial No.161,124.

To all whom it may concern:

Be it known that I,.JosnrH Comer, a citizen of the United States, and a,resident of Worcester, in the county of Worcester and State ofMassachusetts, have invented a new and useful Improvement in Woven P leFabrics, of which the following is a specification.

My invention relates to woven pile fabrics and more particularly toWilton carpets and rugs orother pile fabrics.

One of the objects of my invention is to provide a double-woven rug orcarpet, the two body portions thereof being of. ent1rely differentqualities or types but having the same pattern.

More specifically stated, it is one object of my invention to provide aduplex rug or carpet, the two parts being woven face-toface andsubsequently cut to produce a W11- ton rug or carpet and a second rug orcarpet constituting a fabric of relatively light and soft materialcorresponding, in a general way, to the well-known oriental rugs havingthe same face pattern as the W1lton fabric and showing exactly the samepattern on the back so that the weaver can see' what is being produced,and being very flexible because it has no pattern threads running alongin the body of the fabric.

Another object of my invention is to provide a relatively wide rug orcarpet which is woven without employing the'usual transversely-extendingwires, so that 1 thereby obviate the usual straight rows of loops ofworsted that are present in the customary types of carpets and whereby arelatively large number of rows of pattern to the inc may be produced,each row following the course of a broken line rather than the usualstraight line and which can be woven rapidly because two Wefts can beinserted, one in each fabric at each beat of. the lay.

My invention may best be understood by reference to the accompanyingdrawing, which is an edge view of a carpet or rug, woven in accordancewith my present invention, of a three-shot fabric.

In the regular Wilton rug or carpet, the pile or set of worsted loops isformed by inserting wires under or in the shed or space formed by theraising of the jacquard mechanism for determining the pattern, each wirebeing provided with an end knife or blade which cuts the worsted loopsor pattern-forming threads as the wires are drawn out transversely afterthe worsted loops or pattern-forming threads have been suitably boundinto the ground or body of the rug or carpet by the desired number ofshots or filling-wefts.

There are usually five frames or sets of bobbins employed in weavingWilton rugs or carpets, and only one worsted color thread is raised bythe jacquard mechanism in each aperture or slot of the reed to therebyform the desired pattern, the remaining four color threads being buriedor carried straight along in the body of the fabric, which constitutesthe main reason for the expensiveness of Wilton rugs and carpets.

According to my present invention, however, I produce rugs or carpets ofthe do ablepile type, the two grounds or bodies being woven'face-to-face in order to economize in the necessary amount of theexpensive worsted threads commonly used in the body One defect of thismethod is that a material amount of time is lost by the greatlyincreased number of lowerings and raisings of the color threads from theone fabric to the other during the process of Weaving. On the otherhand, in my present invention the color or pattern-forming threads areraised and lowered back again into the body of the rug 0r carpet at onemovement of the loom or beat of the lay, consequently producing thedouble-pile fabric by the-same number of loom movements and in the sametime as the regular single fabric of the prior art requires. I Myinvention is particularly applicable to relatively wide work, from oneto three yards, for example, where the usual type of wires cannot be,made sufliciently rigid to properly perform their intended functionwithout being relatively bulky and heavy, thus resulting in theproduction of coarsely woven carpet. In the present instance, however,by reason of the fact that no wires are employed, relativelyfinely-Woven Work may be produced by machine, irrespective of the widthof the carpet or-rug.

Referring to the drawings,-thc double-pile fabric shown comprises a mainor lower ground or body 1 and an upper ground or ity, the two iiartsbeing woven face-to-face' thus vary the relative depth of pile upon thetwo bodies. Several colored worsted warps or pattern-forming threads 4and 5, etc., are shown, each extending from themain or lower body 1upwardly and over the back of the. upper ground or body 2 and thencedownwardly into the main body portion again, as clearly indicated by thedifferently marked worsted warps 4 and 5 in the drawing.

Three shots or filling-wefts per worstedloop are employed in each body,and in the upper fabric, one filling-weft 8 being lo cated Within theloop of each worsted thread and two 9 being located between adjacentWorsted threads of different colors.

. Suitable pairs of binding warps 10 and 10, and 11 and 11*" extendthrough the worsted threads in the upper and in the lower ground,respectively, and take the usual wavy course over the upper. shot ineach body portion and under the adjacent lower shot, the two bindingwarps crossing each other in the usual way to securely bind the worstedthreads 4 and 5 into position. If desired, a stufi'er or filler 12,extending straight through the upper fabric 2 between the parallel rowsof filling-wefts 8 and 9 may be utilized. A stufi'er may also beemployed in the lower ground, as is customary, if desired. Y

The rug or carpet is woven by raising any desired portion of thepattern-forming threads by the jacquard mechanism for forming one rowof-loops 4 in spaced sections or groups, according to the desired pattern, upon the first movement of the 100m or beat of the lay and bythrowing the weft or shuttle thread 8 through or acrossthem andpartially binding them into the respective bodies or grounds (notshown), and then upon the second loom movement, raising the remainingpattern threads 5 in the spaces between the first set of groups to thusform a complete and uniform double row of worsted loops, the next weftor shuttle thread 8 being thrown through or across the second row 5 ofworsted loops and the other binding-warps being woven into theillustrated position. The two rows of loops are com actly driventogether by the reed or lay in the usual manner to' form a double courseor row, having an approximately rectangular outline, considered as awhole, but wherein the filling-wefts or shuttle threads 8 follow brokenlines of symmetrically recurring form. Adjacent single courses orrowsare thus dissimilar in both the upper and the lower bodies.

is thus woven in the same time and with the same number of required loommovements as is taken by the weaving of the regular Wilton rugs orcarpets.

Moreover, a relatively large number of rows per inch of pattern-formingthreads is entirely feasible in the present invention, since the numberof rows is not dependent upon the thickness of wires which, of course,limits the number of rows per inch in the regular Wilton work.

A double-pile fabric, employing five different colors of yarn is shown,a three-shot type of filling, however, being employed. In the lower ormain body 20, one shot 21 passes along the back of the ground, while theother two shots or filling-wefts 22 and 23 are located alon the top orup er* surface of the body portion. Each bin ing-warp 11 and 11*,in thiscase extends under the lower shot and over the two upper shots,successively, the two binding-warps being arranged in the usualcomplementary sense or crossing arrangement to produce the desiredbinding effect. The three shots in the upper body are arranged and boundin an analo-' gous manner. This produces a three-shot weave in eachfabric with the pattern reproduced on the back of the upper fabricwithout variation so that if desired the rear loops could be cut by pilewires and the upper fabric would be a double reversible ple fabric wlth'identical" patterns on both s1 es.

It will be seen that I thus provide a double-pile fabric wovenface-to-face, wherein the lower ground or body comprises a regularWilton rug or carpet of a selected pat-v tern and the upper ground orbody has the same pattern, but is of an entirely different quality andweight. In the upper fabric, the pattern or worsted threads are loopedover the back, that is, the upper illustrated surface of the upper body,so that the complete, identically colored and locatedpattern 1s alsoshown on the back. The upper fabric is very light and soft, being inthis respect also somewhat comparable to the oriental rugs and at thesame time the patternthreads are firmly and uniformly bound in the upperfabric and will not draw out or loosen.

If desired to make the upper fabric still lighter and more flexible, thestuifer or filler 12 may be omitted thereby leaving only the bindingwarps and the pattern forming threads. In this case also, such threadswould be firmly bound into the light body,

and a very light and soft rug or carpet would result. I

As previously stated, the cutting or splitting of the worsted loopsalong'the intermediate line 33 to thus form the desired double cut-pilefabric, is referably accomplished by a suitable kni e arrangement as therug or carpet isbeing woven, and the vertical adjustment of such knifewill correspondingly vary the relative depth of pile upon the upper andlower bodies.

I do not wish to be restricted to the specific arrangement of partsherein set forth, as various modifications thereof may be effectedWithout departing from the spirit and scope of my invention. Forexample, the described fabric, in addition to being employed for carpetsor rugs, may also be used as a covering for furniture, etc. I desire,therefore, that only such limitations shall be imposed as are expressedin the appended claim.

I claim as my invention:

A double-woven pile fabric having an upper and a lower body of the samepattern but materially different qualities and comprising sets ofWeft-threads for the back of each body, a plurality of pattern threadsraised from the lower body and all looped over Weft-threads in the backof the upper body to show the identically colored and locatedarrangement of individual pattern threads on both sides'thereof and thenlowered directly into the lower body, the weft threads being located inthe front surface of each body in exactly corresponding positionstherein between adjacent pairs of loops, so that two weft-threads can beintroduced at each beat of the lay, and sets of binding-warps runningsubstantially parallel to each other through the pattern threads of eachbody arranged identically in the two fabrics but reversed andintercrossing to bind in the various Weft-threads and pattern threads.

In testimony whereof, I have hereunto subszcribed my name this 6th dayof April, 191

JOSEPH COLEY.

